Mini Master: Maintenance Management & Technology

Introduction:

Maintenance Best Practices are critical for every successful individual and company. This training course has been designed to benefit both qualified new professionals as well as experienced professionals who might need to refresh their skills. It covers all the fundamentals of Maintenance that a suitably qualified professional would be expected to carry out during his duty starting with the first steps and building up in a staircase fashion to a fully functional maintenance organization. This will provide an ‘MBA level’ experience in terms of content, instruction, discussion and team exercises

Targeted Groups:

• Maintenance Supervisors and Superintendents
• Reliability Engineers
• Operational Professionals who are interested in maintenance reliability and asset management
• Safety and Integrity Professionals
• Other Professionals involved in Process Improvement

Course Objectives:

At the end of this course the participants will be able to:

• Provide a step-by-step guide to maintenance best practice starting with foundations and building up to best practice that will deliver maximum business benefits
• Instruct Maintenance optimization best practice techniques
• Provide opportunities to discuss the application of these best practices
• Provide an opportunity to learn these concepts through practical exercises
• Understand the Maintenance optimization best practice techniques
• Understand a range of equipment failures and their implications to the operational organization
• Design a maintenance plan for the upkeep and maintenance inspections of static and rotating plant

Targeted Competencies:

• Fundamentals of maintenance, reliability and asset management
• Reliability modeling and failure modes for rotating and stationary machinery
• Learning from major failures
• Condition-based maintenance technologies
• Selection of appropriate maintenance strategies in asset management
• Maintenance theory and practice
• Maintenance work processes
• Asset Management
• Failure Analysis
• Preventive Maintenance

Course Content:
Unit 1: An Overview of Key Maintenance Work Processes:

• Introduction to Maintenance Management
• Definitions of key terms
• Types of Maintenance
• Reactive, planned and improvement jobs
• Preventive and Proactive

Unit 2: Maintenance Management Systems:

• Maintenance Planning and Scheduling
• Computerized Maintenance Management Systems
• Developing Maintenance Key Performance Indicators

Unit 3: Preventive Maintenance and Maintenance Strategy:

• Maintenance Organisation Structure and Policies
• Developing and Implementing a Preventive Maintenance Program
• Applying Reliability Based principles to Maintenance Strategy Development

Unit 4: Maintenance Logistics and Cost Control:

• Managing Maintenance Spare Parts and Logistics
• Optimizing Spare Parts Inventory Levels
• Maintenance Budgeting
• Controlling Maintenance Costs
• Introduction to Life Cycle Cost Concepts

Unit 5: Maintenance Team Work:

• Engineering, Production & Maintenance Teams
• Benefits of Integrated teams
• Motivation and empowerment
• Total Productive Maintenance Concepts
• Implementing Team-Based Continuous Improvement in Maintenance

Unit 6: Failure of Machines and Inspection Based Failure Analysis - Causes of Machinery Failure in Rotating Equipment:

• Cavitation in Pumps
• Tripping of Turbines
• Surging in Compressors
• Wear Mechanisms: Fatigue, Fretting, and Corrosion
• Fundamental Machine Problems: Balance Problems, Alignment Problems, Machinery Mounting Problems
• Fundamentals of Maintenance and Asset Management

Unit 7: Failure Analysis and Reliability:

• Elementary Statistics and Standards
• Reliability Models
• Learning from Major Failures Case Studies in Process Industries
• Learning from Major Failures Case Studies in Oil and Gas Industries
• Root Cause Analysis and Extractions of Specific and Generic Lessons
• Reflection on Why Systems Fail

Unit 8: Statistical Failure Analysis and Reliability:

• Further Reliability Definitions and Standards
• Examples of the Planning Process
• Hazard Function and Bath Tub Curve
• Weibull Analysis

Unit 9: Condition Based Maintenance:

• General Purpose CBM
• The P-F Curve
• Principles of Vibration Monitoring
• Thermal Monitoring
• Acoustic Emission
• Lubricant Monitoring

Unit 10: Decision Analysis in Asset Management:

• Main Criticism of Existing Management of Computerised Maintenance Systems
• The Asset Management Framework
• The Decision-Making Grid Approaches
• Selection of Appropriate Maintenance Strategies
• Integration of RCM, TPM and CBM Approaches